Z-Shaped Building Materials

ABSTRACT

A z-shaped building material includes a base defining a z-shape configuration and at least one break-line disposed on an exterior surface of the base such that a geometric pattern of the z-shaped building materials creates a three-dimensional visual appearance. A reveal is disposed around an outer periphery of the base for receiving mortar to join together adjacent building materials. The base is formed from a material selected from the group consisting of clay, clay and straw, clay-bearing soil, sand and lime, cement, concrete and mixtures thereof. The z-shaped building material may be a masonry brick having a dimension of about eight inches in a height direction and a dimension of about eight inches in a width direction. The z-shaped building material may be a face brick having a dimension of about eight inches in a height direction and a dimension of about eleven and five-eighths inches in a width direction.

CROSS-REFERENCE To RELATED APPLICATION

This U.S. non-provisional patent application claims benefit of thepriority of the filing date of U.S. provisional patent Application No.63/031,072 filed on May 28, 2020.

FIELD OF THE INVENTION

This invention relates generally to building materials, such asconstruction and landscaping materials, and more particularly, tobuilding materials that are z-shaped. In an advantageous exemplaryembodiment, the invention is a masonry construction product having az-shape.

BACKGROUND OF THE INVENTION

Bricks and pavers have long been used for construction and landscaping.Fired bricks, also known as artificial stone, have been around since atleast about 4000 BC. Historically, bricks were composed of clay, or clayand straw. Contemporary bricks are made from clay-bearing soil, sand andlime, cement or concrete materials. The term “bricks” commonly refers tounits of building materials that are joined together by mortar, adhesiveor interlocking features.

Bricks are used as building materials to make walls, pavements and othermasonry structures. For purposes of convenience in manufacturing andconsistency in configuration, bricks are typically formed in cuboidblocks having an elongated rectangular shape. The rectangular shapeallows bricks to be assembled in horizontal linear rows, generallyreferred to as courses. Courses of bricks are laid one upon the other toform a vertical wall of a structure. The courses may be staggeredrelative to adjacent courses in order to better distribute the force ofvertical loads, as well as to produce an aesthetic visual appearance.Bricks of varying colors and textures may also be used to provide afurther aesthetic appearance.

For centuries the rectangular shape of conventional bricks has servedstandard construction and landscaping well. However, laying courses ofrectangular bricks is labor intensive and time consuming, particularlywhen the bricks are of a relatively small size. Furthermore, it is oftendesirable in contemporary building construction to create an aestheticvisual effect, such as an accent wall, by arranging the bricks in ageometric pattern other than horizontal rows. It is even more laborintensive and time consuming, and thus even more costly, to arrangerectangular bricks in a geometric pattern other than horizontal courses.

It is therefore apparent a need exists for a building material thatovercomes the known deficiencies of rectangular bricks. A particularneed exists for a building material that is less labor intensive andtime consuming to use when constructing a vertical wall of a structure.The building material needs to provide at least the same, if notsuperior, capacity to distribute the force of vertical loads. Thebuilding material further needs to produce a desirable aestheticappearance when the building material is arranged in a geometric patternother than horizontal courses. It is desirable that the buildingmaterial is in the form of bricks having a shape other than rectangularthat is made from conventional material and in various colors andtextures.

Certain aspects, objects, features and advantages of the presentinvention will be made apparent, or will be readily understood andappreciated by those skilled in the relevant art, as exemplaryembodiments of the invention shown in the accompanying drawing figuresare described in greater detail hereinafter. It is intended that allsuch aspects, objects, features and advantages of the inventionenvisioned by this disclosure of exemplary embodiments be encompassed bythe scope of protection of the appended claims, given their broadestreasonable interpretation and construction in view of the prior art.These aspects, objects, features and advantages of the invention, aswell as others not expressly disclosed, may be accomplished by any ofthe exemplary embodiments described herein and illustrated in theaccompanying drawings. However, it should be appreciated that thedrawing figures are for illustrative purposes only, and that manymodifications, changes, revisions and substitutions may be made to anyof the exemplary embodiments without departing from the general conceptsof the invention as they may be broadly construed and interpreted.

BRIEF DESCRIPTION OF THE DRAWINGS

The aforementioned aspects, objects, features and advantages of thepresent invention will be more fully understood and appreciated whenconsidered in conjunction with the accompanying drawing figures, inwhich like reference characters designate the same or similar partsthroughout the several views.

FIG. 1 is a front elevation view showing a typical layout ofconventional bricks according to the prior art.

FIG. 2 is a front elevation view showing a typical layout of z-shapedbuilding materials according to the present invention.

FIG. 3 is a front elevation view of a typical z-shaped building materialaccording to a first exemplary embodiment of the present invention.

FIG. 4 is a front elevation view of a typical z-shaped building materialaccording to a second exemplary embodiment of the present invention.

FIG. 5 shows various views of the z-shaped building material shown inFIG. 4.

FIG. 6 is a front elevation view of a building constructed withconventional bricks and z-shaped building materials according to thepresent invention illustrating an aesthetic visual appearance producedby the geometric pattern of the z-shaped building materials.

FIG. 7 is a front elevation view of a monument constructed withconventional bricks and z-shaped building materials according to thepresent invention illustrating an aesthetic visual appearance producedby the geometric pattern of the z-shaped building materials.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following is a detailed description of one or more exemplaryembodiments of z-shaped building materials formed in accordance with thepresent invention. Each exemplary embodiment is described more fullyhereinafter with reference to the accompanying drawing figures. In eachexemplary embodiment shown and described herein, the z-shaped buildingmaterial is useful for construction and landscaping. In particular,z-shaped building materials according to the invention are useful forreplacing conventional bricks and pavers in construction and landscapingprojects.

The z-shaped building materials may be made of any suitable materialthat is formable into the desired “z” shape, while retaining sufficientstrength and stiffness for use in the construction of a vertical wall ofa structure. Preferably, but not necessarily, the z-shaped buildingmaterial is made of the same or similar materials as conventional bricksand pavers. By way of example and not limitation, the z-shaped buildingmaterial may be made of clay, clay and straw, clay-bearing soil, sandand lime, cement or concrete materials, or mixtures thereof. Thez-shaped building material may also be made in any suitable color ortexture to produce a desirable aesthetic effect.

In a particularly advantageous embodiment, the z-shaped buildingmaterial is a masonry construction product. In the exemplary embodimentsdescribed herein and illustrated by the accompanying drawing figures,the z-shaped building material is a brick useable for construction inthe same manner as a conventional brick or useable for landscaping inthe same manner as a conventional brick or paver. The z-shaped brick maybe in the form of solid masonry wherein the brick supports the buildingstructure. Alternatively, the z-shaped brick may be in the form of brickveneer wherein the building structure, for example an underlying wood ormetal frame, or concrete wall, supports the brick veneer. The primarydifference between the z-shaped brick, also referred to herein as“masonry brick,” and the z-shaped brick veneer, also referred to hereinas “face brick,” is the greater thickness in the depth direction of themasonry brick relative to the face brick.

FIG. 1 is a front elevation view showing a typical layout ofconventional bricks 10 historically used in construction andlandscaping. The generally rectangular bricks 10 are arranged in apattern of horizontal rows, generally referred to as courses 12. Thecourses 12 of bricks 10 may be staggered relative to adjacent courses 12in order to provide greater strength and stability by betterdistributing the force of vertical loads. The staggered courses 12 ofbricks 10 also serve to produce a more aesthetic visual appearance to avertical wall of a structure. The bricks 10 may also be of varyingcolors or textures to provide a further aesthetic appearance. The bricks10 may be of any desired height, width and depth (thickness) dimensionssuitable for a particular construction or landscaping application.

FIG. 2 is a front elevation view showing a typical layout of z-shapedbuilding materials 20 according to the present invention. The z-shapedbuilding materials 20 depicted in FIG. 2 may, for example, be in theform of masonry brick or face brick. Regardless, the z-shaped buildingmaterials 20 are arranged in a pattern 22 that produces an aestheticvisual appearance. In particular, the pattern 22 produces a perceptionthat a vertical wall of a structure is three-dimensional when viewed bya person from a sufficient distance. Thus, z-shaped building materials20 produce a three-dimensional illusion or effect on the vertical wallof the structure that provides an aesthetic visual appearance. At thesame time, the z-shaped building materials 20 provide at least the sameor superior distribution of the force of vertical loads on the verticalwall of the structure, as will be explained in greater detailhereinafter. If desired, the z-shaped building materials 20 may also beof varying colors or textures to provide a further aesthetic appearance.

FIG. 3 is a front elevation view of a typical z-shaped building material30 according to a first exemplary embodiment of the present invention.The z-shaped building material 30 is in the form of a masonryconstruction product (e.g. masonry brick or face brick) or a landscapingpaver. For purposes of illustration only, the exemplary embodimentdepicted in FIG. 3 is a z-shaped masonry brick 30. The z-shaped masonrybrick 30 may have any dimensions suitable for a particular buildingconstruction or landscaping application. As shown herein in aparticularly advantageous example, the z-shaped masonry brick 30 has adimension of about eight inches (8″) in a height direction H, and anoverall dimension of about eight inches (8″) in a width direction W.However, the masonry brick 30 may have a dimension between about eightinches (8″) and about twelve inches (12″) in the height direction H. Themasonry brick 30 generally has a dimension of between about two inches(2″) and about four inches (4″) in a depth or thickness direction T (seeFIG. 5). Regardless, the dimensions of the masonry brick 30 allow it tobe used seamlessly in conjunction with standard rectangular bricks 10 toprovide a further unique aesthetic visual appearance. The z-shape of themasonry brick 30 provides more resting points on a vertical wall of astructure, and consequently, results in a stronger vertical rise thanbricks 10.

As shown herein, the masonry brick 30 has a beveled edge, also referredto herein as a reveal 32, around its entire outer periphery forreceiving mortar to join adjacent masonry bricks 30. The reveal 32extends inwardly in the thickness direction T from the exterior surfaceof the masonry brick 30 along the outer periphery of the masonry brick30. Reveal 32 may have any suitable dimension, or extent, in thecorresponding height direction H or the corresponding width direction W,as applicable. In a particular example, however, the extent of thereveal 32 is about one-half inch (½″). Regardless, the reveal 32 createsan aesthetic deeper rolled appearance on the exterior surface of themasonry brick 30. As shown herein, the masonry brick 30 is furtherprovided with an indented break-line 34 having an extent of aboutone-quarter inch (¼″) to about one-half inch (½″). The break-line 34 onthe exterior surface of the masonry brick 30 creates a subtlethree-dimensional illusion or effect when viewed by a person from asuitable distance. In addition, the break-line 34 leaves a clean andeven break when a portion of the masonry brick 30 is broken off toconform to the geometry of the construction or landscaping application.

FIG. 4 is a front elevation view of a typical z-shaped building material40 according to a second exemplary embodiment of the present invention.The z-shaped building material 40 is likewise in the form of a masonryconstruction product or landscaping paver. However, the exemplaryembodiment depicted in FIG. 4 in contrast is a z-shaped face brick 40.The z-shaped face brick 40 may have any dimensions suitable for buildingconstruction or landscaping. As shown herein in a particularlyadvantageous example, the z-shaped face brick 40 has a dimension ofabout eight inches (8″) in a height direction H, and an overalldimension of about eleven and five-eighths inches (11⅝″) in a widthdirection W. However, the face brick 40 may have a dimension betweenabout eight inches (8″) and about twelve inches (12″) in the heightdirection H. The face brick 40 generally has a dimension of betweenabout one-half inch (½″) and about two inches (2″) in a thicknessdirection T (see FIG. 5). Regardless, the dimensions of the face brick40 allow it to be used seamlessly in conjunction with standardrectangular bricks 10 to provide a further unique aesthetic visualappearance. The z-shape of the face brick 40 provides more restingpoints on a vertical wall of a structure, and consequently, results in astronger vertical rise than bricks 10.

As shown herein, the face brick 40 has a beveled edge, also referred toherein as a reveal 42, around its entire outer periphery for receivingmortar to join adjacent face bricks 40. The reveal 42 extends inwardlyin the thickness direction T from the exterior surface of the face brick40 along the outer periphery of the face brick 40. The reveal 42 mayhave any suitable dimension, or extent, in the corresponding heightdirection H or the corresponding width direction W, as applicable. In aparticular example, however, the extent of the reveal 42 is aboutone-half inch (½″). Regardless, the reveal 42 creates an aestheticdeeper rolled appearance on the exterior surface of the face brick 40.As shown herein, the face brick 40 is further provided with an indentedbreak-line 44 having an extent of from about one-quarter inch (¼″) toabout one-half inch (½″). The break-line 44 on the exterior surface ofthe face brick 40 creates a subtle three-dimensional illusion or effectwhen viewed by a person from a suitable distance. In addition, thebreak-line 44 leaves a clean and even break when a portion of the facebrick 40 is broken off to conform to the geometry of the construction orlandscaping application.

FIG. 5 shows various views of the z-shaped face brick 40 shown in FIG.4. The various views include a front elevation view, a left-hand sideelevation view, a right-hand side elevation view, and a top plan viewthat illustrate additional details of a typical face brick 40. In theillustrated embodiment, the face brick 40 optionally includes mechanicalretention grooves 46 formed on the interior surface of the rear of theface brick 40. The retention grooves 46 ensure that the relatively thinface bricks 40 remain firmly adhered to a vertical wall of a structure.The optional retention grooves 46 preferably have an extent of betweenabout one-half inch (½″) and about one inch (1″) in the thicknessdirection T.

FIG. 6 is a front elevation view of a building 50 constructed withz-shaped building materials 20 according to the present invention. FIG.7 is a front elevation view of a monument structure 60 constructed withz-shaped building materials 20 according to the present invention. Theelevation of the building 50 and the monument structure 60 eachillustrate an aesthetic visual appearance produced by the geometricpattern of the z-shaped building materials 20. If desired, the building50 or the monument structure 60 may be constructed using the z-shapedbuilding materials 20 in conjunction with conventional bricks 10 tofurther the unique aesthetic appearance of the building 50 or monumentstructure 60. The conventional bricks 10 may be modular and of astandard size suitable for construction with the z-shaped buildingmaterials 20.

In view of the foregoing detailed description and the accompanyingdrawing figures, it will be apparent to those skilled in the art thatthe z-shaped building materials 20 of the present invention provide anovel and non-obvious masonry construction and landscaping product. Thez-shaped building materials 20 and indented break-lines 34, 44 create anaesthetic visual appearance, and in particular, a three-dimensionalillusion or effect when a vertical wall of a structure is viewed by aperson from a sufficient distance. The structural integrity and strengthof the z-shaped building materials 20 equals or exceeds that ofconventional bricks 10 and traditional construction methods.Specifically, z-shaped building materials 20 according to the inventionprovide more resting points for a stronger vertical rise, while reducingmaterial waste. The unique interlocking design of the z-shaped buildingmaterials 20 along with strategically-placed mechanical retentiongrooves 46 ensures that a vertical wall of a structure remains firmlyadhered to the structure.

The z-shaped building materials 20 of the present invention provide aversatile product that has any number of construction and landscapinguses. In addition to masonry wall construction for residential andcommercial buildings and other structures, the z-shaped buildingmaterials 20 may be used as pavers to create herringbone design interiorfloors, pavements, walkways, driveways and patios. The z-shaped buildingmaterials 20 may also be used to create hardscape areas around pools andspas, as well as landscape retaining walls and features, such asvertical waterfall structures. Finally, z-shaped building materials 20according to the present invention can be manufactured from the samematerials, in the same colors and textures, and in the same manner asconventional bricks 10 using a specialized mold configured to producethe unique z-shape of the modular z-shaped building materials 20.

Regardless of the foregoing detailed description of exemplaryembodiments of the invention, the optimum configuration of the articleof manufacture, apparatus, device or system, and the manner of use,operation and steps of the associated methods, as well as reasonableequivalents thereof, are deemed to be readily apparent and understood bythose skilled in the art. Accordingly, equivalent relationships to thoseshown in the accompanying drawing figures and described in the writtendescription are intended to be encompassed by the present inventiongiven the broadest reasonable interpretation and construction of theappended claims, the foregoing being considered as illustrative only ofthe general concept and principles of the invention(s). Furthermore, asnumerous modifications and changes will readily occur to those skilledin the art, the exemplary embodiments are not intended to limit theinvention to the specific configuration, construction, materials, mannerof use and operation shown and described herein. Instead, all reasonablypredictable and suitable equivalents and obvious modifications to theinvention should be construed as falling within the scope of theinvention as defined by the appended claims given their broadestreasonable interpretation and construction as would be understood bythose skilled in the art in light of the foregoing written descriptionand accompanying drawing figures in view of the relevant prior art.

That which is claimed is:
 1. A z-shaped building material, comprising: abase defining a z-shape configuration; and at least one break-linedisposed on an exterior surface of the base; wherein a geometric patternformed by a plurality of the z-shaped building materials creates anaesthetic three-dimensional visual appearance.
 2. The z-shaped buildingmaterial according to claim 1, further comprising a reveal disposedaround at least a portion of an outer periphery of the base.
 3. Thez-shaped building according to claim 1, wherein the base is formed froma material selected from the group consisting of clay, clay and straw,clay-bearing soil, sand and lime, cement, concrete and mixtures thereof.4. The z-shaped building material according to claim 1, wherein thez-shaped building material is a masonry brick having a dimension ofabout eight inches (8″) in a height direction and a dimension of abouteight inches (8″) in a width direction.
 5. The z-shaped buildingmaterial according to claim 1, wherein the z-shaped building material isa face brick having a dimension of about eight inches (8″) in a heightdirection and a dimension of about eleven and five-eighths inches (11⅝″)in a width direction.
 6. The z-shaped building material according toclaim 1, wherein the z-shaped building material has a dimension ofbetween about eight inches (8″) and about twelve inches (12″) in aheight direction, and/or wherein the z-shaped building material has adimension of between about eight inches (8″) and about eleven andfive-eighths inches (11⅝″) in a width direction.
 7. A z-shaped buildingmaterial for construction and landscaping, comprising: a base defining az-shape configuration having an overall dimension of about eight inches(8″) in a height direction and a dimension of between about eight inches(8″) and about twelve inches (12″) in a width direction; at least onebreak-line disposed on an exterior surface of the base; and a revealextending around at least a portion of an outer periphery of the base.8. The z-shaped building material according to claim 7, wherein ageometric pattern formed by a plurality of the z-shaped buildingmaterials creates a three-dimensional visual appearance.
 9. The z-shapedbuilding material according to claim 7, wherein the base is formed froma material selected from the group consisting of clay, clay and straw,clay-bearing soil, sand and lime, cement, concrete and mixtures thereof.10. The z-shaped building material according to claim 7, wherein thez-shaped building material is a masonry brick.
 11. The z-shaped buildingmaterial according to claim 7, wherein the z-shaped building material isa face brick.
 12. The z-shaped building material according to claim 7,wherein an extent of the at least one break-line is from aboutone-quarter inch (¼″) to about one-half inch (½″).
 13. The z-shapedbuilding material according to claim 7, wherein an extent of the revealis about one-half inch (½″).
 14. The z-shaped building materialaccording to claim 7, further comprising at least one retention grooveformed on an interior surface of the rear of the base.
 15. The z-shapedbuilding material according to claim 14, wherein an extent of the atleast one retention groove is between about one-half inch (½″) and aboutone inch (1″).
 16. The z-shaped building material according to claim 8,wherein the geometric pattern creates a three-dimensional visualappearance on a building.
 17. The z-shaped building material accordingto claim 8, wherein the geometric pattern creates a three-dimensionalvisual appearance on a monument structure.